Apparatus for applying terminals from a carrier strip to wire

ABSTRACT

Apparatus mounting crimping dies and feeding means for crimping successively fed terminals and dislodging the crimped terminals from a feeding carrier, by synchronized relative movement between the crimping dies and carrier feeding means.

United States Patent [191 Mille APPARATUS FOR APPLYING TERMINALS FROM ACARRIER STRIP TO WIRE [75] Inventor: James E. Miller, Westville, NJ.

[73] Assignee: Minnesota Mining and Manufacturing Company, Saint Paul,Minn.

[22] Filed: Nov. 22, 1972 [211 Appl. No.: 308,689

[52] US. Cl. 29/203 DT [51] Int. Cl H0lr 43/04 [58] Field of Search29/203 D, 203 R, 203 S,

[4 1 June 4,1974

[56] References Cited UNITED STATES PATENTS 3,516,157 6/1970 Brown29/203 D X 3,553,814 1/1971 Rider 29/203 D 3,590,481 7/1971 Felty 29/203D Primary ExaminerThomas H. Eager 5 7 1 ABSTRACT Apparatus mountingcrimping dies and feeding means for crimping successively fed terminalsand dislodging the crimped terminals from a feeding carrier, bysynchronized relative movement between the crimping dies and carrierfeeding means.

4 Uaims, 9 Drawing Figures PATENTEUJUH 41914 SHEET 3 [1F 4 PATENTEBJUN41974 333113.753

SHEET I; (If 4 BACKGROUND OF THE INVENTION The high speed and largequantity application of wire terminals to wires has, heretofore, beensubject to substantial difficulties, both in involving relativelycomplex and unreliable equipment, subject to frequent malfunc tion andbreakdown, as well as being relatively slow and of limited output permachine, so that undue members of machines and operators were required.

More particularly, one major difficulty encountered in prior relativelyhigh rate terminal crimping proce dures was that of rapid, reliable andprecise feeding of terminals to the crimping dies. The apparatus of theinstant application utilizes terminal carrier strip means or tape, suchas that disclosed in my copending US. Pat. application Ser. No. 243,781,filed Apr. 13, 1972.

SUMMARY OF THE INVENTION It is, therefore, an important object of thepresent invention to provide apparatus for applying terminals to wireswhich utilizes strip carried terminals for accurate and dependablefeeding of the terminals to a crimping station, where wire ends areassociated with the fed terminals to be crimped together, and thecrimped terminal together with the associated wire is separated from thecarrier strip by relative movement between the crimping means and stripfeeding means.

It is a further object of the present invention to provide terminalapplying apparatus of the type described which is capable of use inconjunction with a wide variety of terminal sizes and styles, as by mereinterchange of crimping dies, the terminals being automatically andprecisely positioned at the crimping station for a crimping operationresponsive to proper location of a wire end, and wherein wire ends maybe fed manually, if desired, while the apparatus permits of automaticwire end feeding to the terminal applying apparatus.

It is still another object of the present invention to provide aterminal applying apparatus having the advantageous characteristicsmentioned in the preceding prargraphs which is entirely safe andfoolproof in operation, durable and reliable throughout a long usefullife, and extremely simple in construction for economy of manufactureand maintenance.

Other objects of the present invention will become apparent upon readingthe following specification and referring to the accompanying drawings,which form a material part of this disclosure.

The invention accordingly consists in the features of construction,combinations of elements, and arrangements of parts, which will beexemplified in the construction hereinafter described, and of which thescope will be indicated by the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a front elevational viewshowing the terminal applying apparatus of the present invention in anon-crimping position, partly broken away for clarity.

FIG. 2 is a sectional elevational view taken generally along the line2-2 of FIG. 1, showing interior construction.

FIG. 3 is a rear elevational view of the apparatus of FIG. 2, as fromthe right-hand side thereof, with parts broken away for ease ofunderstanding.

FIG. 3A is a perspective view of the upper members in FIG. 3.

FIG. 4 is a partial sectional elevational view taken generally along theline 4-4 of FIG. 2.

FIG. 5 is a partial sectional view taken generally along the line 5--5of FIG. 2, but showing the dies in closed position.

FIG. 6 is a sectional elevational view taken generally along the line6-6 of FIG. 5.

FIG. 7 is a partial perspective view illustrating a terminal feedingcarrier strip for use in the instant apparatus, prior to crimping.

FIG. 8 is a perspective view similar to FIG. 7, but illustrating thecarrier strip and a terminal after crimping and separation from thestrip.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now more particularlyto the drawings, and initially to FIGS. 7 and 8 thereof, a carrier,strip or tape is generally designated 20, and may include an elongateflexible sheet 21, say of plastic sheeting, or other material capable ofbeing coiled, as for convenience in storage, shipment and use. The sheet21 may be provided at one longitudinal region, say along one side edge22, with feed elements 23, such as sprocket holes or other suitable feedelements for cooperation with strip feeding means, as will appear morefully hereinafter.

Additionally, the sheet 21 may be provided, as by deformation, see FIG.8, with receivers or sockets 25 adjacent to the opposite longitudinalside edge 26, for receiving portions of respective terminals 27. Thus,the enlarged end or head of each terminal 27 may be conformably receivedin a respective carrier deformation 25, with the barrel or remainder ofthe terminal extending beyond the adjacent carrier edge 26. A securementmember or adhesive tape or strip 28 may be applied over the receivedportions or heads of terminals 27 to releasably retain the latter intheir receiving deformations 25.

The carrier 20 and associated terminals 27, as shown in FIG. 7,illustrate the condition prior to crimping assembly with respect to awire end. FIG. 8 illustrates the carrier 20 and a terminal 27a asassociated with a wire end 30, being crimped thereon. Further, thecrimped terminal 27a is illustrated as having been separated ordisassociated from the carrier 20, as by movement along the direction ofarrow 31.

Considering now the terminal applying apparatus of the present inventionshown in FIGS. 1-3, being essentially a press and generally designated40, the press 40 may include a generally horizontal base member or plate41, from which upstand a pair of generally parallel, upright sidemembers or plates 42. The side pieces or plates 42 are each formed at avertically intermediate location with a forwardly opening cutout 43. Abed member or plate 44 extends laterally between the pair of spaced sidemembers 42, being disposed generally horizontally and suitably securedto the side members in lower regions of the cutouts 43. A lateral framemember or spreader bar 45 extends between rearward regions of the sidemembers 42, rearwardly of the cutouts 43. Additionally, a top member orblock 46 is disposed generally horizontally and extends laterallybetween upper regions of the side members 2, being suitably fixedthereto.

The structure thus far described may be considered as the framework of apress, including the upright side pieces 42, press bed 44, rear framemember 45 and top member 46.

The top member or block 46 may be formed with a generally horizontal,forwardly and rearwardly extending through bore 50 having journalbushings therein, as at 51, and provided with lubricating means, such asoil cups 52, all for rotatably receiving a flywheel shaft 53 journaledin the block 46.

The shaft 53 extends rearwardly beyond the upper regions of side plates42, overhanging the journal block 46, as at 54, and there carries aflywheel 55 rotatably journaled on the overhanding shaft region, as by ajournal bushing 56. The flywheel 55 is suitably driven, as byappropriate transmission means, say a belt 57 engaged in flywheel groove58, being trained about both the flywheel and a drive pulley 59 on theshaft of a drive motor 60.

The flywheel 57 is suitably retained in rotative relation on the shaftextension 54, as by a thrust bearing 61, and collar 62, both on the rearend region of the shaft extension. Forwardly of the pulley 55,circumposed about the shaft 53 and associated therewith in disengageabledriving relation, as through a collar 65, or other suitable means, thereis provided a clutch 66. The clutch 66 may be conventional, and, asappears more fully hereinafter, may be of the single revolution typewherein the shaft 53 may be coupled in driven relation with respect tothe flywheel 55 for a single rotation of the shaft (or other suitablelimited annular displacement) upon each actuation of the clutch.

Crank means, as in the form of an eccentric 67 may be fixed to theforward region of shaft 53 for rotation therewith, and a connecting rod,arm or pitman 68 may include a crank portion 69 rotatably journaledabout the circumference of eccentric 67, as by a journal bushing 70.Suitable lubrication means, such as an oil cup ii and appropriatepassageways, may afford the necessary lubrication to the crank endportion 69 of connecting rod 68. The other end of the connecting rod 6%depends to a generally cylindrical formation or wrist pin 72. Anadjustable braking means, as at 73, may assume the form of a block '74having one end anchored, as by a fastener 75 to one of the frame sides42, the left frame side as seen in HQ. ll. The block 74 is formed witha. generally circular through opening 76 receiving the forward endregion of shaft 53, and the block is split, as by a slot 77 to define apair of resilient legs 7% and 79 for adjustable frictional brakingengagement with the received portion of shaft 53. Braking adjustment isobtained by a fastener 80 applying a resilient clamping force, asthrough spring 811 to the legs 75? and 79.

Along the forward region of each side plate 42, on the inner sidethereof above the respective cutout 43, there are provided a pair ofgrooved blocks, guides or slideways 85, see FIG. 1. The slideways 35extend generally vertically in parallel spaced relation, having theirfacing sides grooved for slidably receiving a crosshead, generallydesignated 86. That is, the guideways or blocks 85 are suitably fixed torespective side plates 42 to define vertically disposed ways over thepress bed 44. The crosshead 86 is vertically slidable in the guideways85 and connected to the pitman 68, for vertical up and down movement ofthe crosshead upon rotation of shaft 53.

More specifically, the crosshead 86 includes a crosshead body or block87 disposed between said guide members or blocks and having its oppositeside edges slidably received in the facing grooves of the guide members.Formed in the upper end of crosshead block 87 is a generallycylindrical, forwardly and rearwardly extending bore 88, which opensupwardly through the upper end of the crosshead body and rotatablyreceives the lower end wrist pin formation 72 of the connecting rod 68.In this manner the connecting rod 68 is connected to the crosshead body87 for vertical movement therewith and oscillatory rotative movementrelative to the latter.

in addition, the crosshead body 87 is formed, generally mediallythereof, with a forwardly and rearwardly disposed, generally cylindricalrecess or cavity 89 adapted to receive a rotary adjustment cam Q0. Thecam 90 is formed on its periphery with a flat 911, which mergessmoothly, as by a spiral surface 92, with the remainder of theperiphery.

The generally cylindrical recess 89 of crosshead body 87 opens generallyvertically downwardly, as by a groove or slot 93, in which is located aslidable block 94 and a rotary cam 95 having one or more peripheralflats, as at 96, 97 and 98. As best seen in FIG. 4, the block 94 mayhave its upper surface in engagement with its adjustment cam 90. Thus,by selective location of the adjustment cam 90, the block 94- isadjusted vertically in the slot 93. Additionally, the rotary adjustmentmember 95 is selectively rotatively shiftable to place a desired flatsurface 96, 97 or 98 in downwardly facing relation. As the flat surfaces96, 97 and 98 are chordal and at different radii, it will be understoodthat each such surface will be located at a different vertical positionin the slot 93.

The crosshead 86 further includes a pair of front and rear crossheadplates 100 and 101 secured on the front and rear surfaces, respectively,of the crosshead body 87. The front crosshead plate Mill may be providedwith an arcuate scale 102, generally concentric with the adjustment cam90, and a manually actuable knob Hi3, and associated pointer 104, may besecured to the adjustment cam 98 for selectively effecting rotationthereof and calibrating the selected position of rotation. Further, therotary, plural-sided cam 95 may include a manually actuable extensionQ6, say cross slotted for a screwdriver, and rotatable to place aselected flat 96, 97 or 98 in downwardly facing relation.

One die member 105 of crimping dies is disposed in the slot 93, with itsupper end in abutting engagement with the downwardly facing surface ofrotary cam 95. That is, the downwardly facing surface of rotary cam 95determines the elevation of crimping die number 105, and the die memberis suitably secured at this predetermined elevation by an suitablemeans, such as one or more set screws in the die body 87.

ln certain applications, as in the crimping of insulated terminals orterminals having an insulating sleeve, it is sometimes advantageous toemploy split dies, say having forward and rearward sections separatelyadjustable to achieve selectively desired crimping action at differentlocations and according to the thickness of insulation. For thispurpose, the cam 95 may serve to selectively adjustably position onesection of a split die relative to another section, as required by thecircumstances.

Fixedly mounted on the upwardly facing press bed 45 is a die holder orblock 110, which is provided with a generally vertical slot or groove111, in substantial alignment with the groove 93 of crosshead 86, forholding a lower die element 1 12 in cooperating relationship with theupper die element 105. The upper and lower die elements 1115 and 112are, of course, replaceable with other die elements, and have theirworking faces specifically configured for crimping engagement with wireterminals of a particular type and size.

A generally forwardly and rearwardly extending, horizontal rod or way113 extends between the die block 110 and frame member 45, see FIG. 2.The rod 113 may be suitably fixed in position, as by a fastener 114.Slidably circumposed about the rod or way 113, generally coaxiallytherewith, is a generally cylindrical carrier drive member 115. That is,the cylindrical carrier drive member 115 is rotatably and longitudinallyslidable or shiftable on the rod 113, and fixedly carried on its forwardend a toothed feed member or sprocket wheel 116. Thus, the carrier feedmember or sprocket wheel 116 rotates with the drive member 115 coaxiallyof the shaft 113 and is shiftable with the drive member forwardly andrearwardly toward and away from the crimping dies 105 and 112.

Intermediate the ends of the cylindrical drive member 115, there isformed thereon an annular, circumferential groove 117, for a purposeappearing presently. Projecting rearwardly from the rear end of thedrive member 115 are a plurality of index members or pins 118, beingarranged in a circular array about and concentric with the rod 113 inequiangularly spaced relation with respect to each other. Suitableresilient means, such as a coil compression spring 119 is circumposedabout the rod 113 between fixed frame member 45 and drive member 115 maybe employed to resiliently urge the latter toward its forward positionof longitudinal shifting movement.

Additional guide members or ways 125 upstand fixedly between the sideplates 43 and there mount a crosshead or slide member 126 for up anddown vertical movement generally over the drive member 115. Thecrosshead or slide member 126 is provided with a forwardly opening notch127 and formed with an oblique, downwardly and forwardly facing camsurface 128. A drive bracket 1311 is suitably fixed to the rear ramplate 161, projecting rearwardly therefrom and into the notch or groove127 for effecting vertical reciprocation of crosshead 126 together withthat of the crosshead or ram 86.

A drive member shifting means, lever or yoke 131 is disposed generallyvertically between the nether carrier drive cylinder 115 and upperreciprocable cam member 126, including a generally horizontal, laterallyextending pivotal mounting member or pin 132 carried by a fixed block133. The shifting member 131 includes an upper lever or arm 134upstanding from the pivot 132 and carrying on its upper end a camfollower or roller 135. Depending from the pivot 132, the drive member131 includes a bifurcated lever or yoke portion 136 having inwardlyprojecting pins or gudgeons entering slidably into peripheral groove117.

Thus, upon oscillatory rotation of shifting member 131 about its pivotalmounting 132, the drive member or cylinder 115 is caused to shiftforwardly and rearwardly along the way member 113. Further,reciprocation of crosshead 86 effects; through bracket 130,reciprocation of cammed crosshead 126, the cam surface 128 engaging withand operating upon the cam follower or roller to oscillate the shiftmember 131 to shift the drive member 115 rearwardly upon each downwardstroke of the crosshead 86.

Operating mechanism for the clutch 65 may be best seen in FIG. 3, therebeing a mounting plate 140 carried by a bracket 141 fixed to a sideplate 43. A normally generally horizontally disposed trip lever 142 ispivoted intermediate its ends, as by pin 143 to the mounting plate 141).Resilient means, such as a coil extension spring 144 urge the trip lever142 counterclockwise, as seen in FIG. 3, toward a limiting position inabutting engagement with a stop member or pin 145. An upper trip lever146 is pivotally mounted at one end, as by the pin 147, to the supportbracket 141 and extends therefrom over the shaft 54. The coil extensionspring extends between the upper and lower trip 1evers 146 and 142, tonormally urge the latter toward each other. A trip latch 148 ispivotally connected at one end, as at 149, to one end of the lever 142,and upstands therefrom toward the free end of lever 146. The latch 148is provided on its upper end with a lever receiving formation or notch150. An additional resilient means or coil extension spring 151 isconnected between the latch and the lower trip lever 142 to urge thelatch toward the shaft 54 and toward lever 146. Carried by the shaft 54is a clutch deactivating or disengaging member 152, and a non-repeatsegment 153. The underside of trip lever 146 is formed with an undercuthaving an abutment edge 154 for holding engagement with the clutchdeenergizing member 152 to deenergize the clutch. The non-repeat segment153 is generally coplanar with the trip latch 148 to shift the latteroutward upon each shaft revolution and permit downward movement of triplever 146 into retaining engagement with clutch deenergizing member 152.

Suitable actuating means for effecting clutch deenergization, andconsequent rotation of shaft 54 may be provided, say in the form of asolenoid 158 mounted for vertical shifting movement and connected by alink 159 to the lower trip lever 142 to swing the latter clockwise, asseen in FIG. 3 against the force of spring 144. This raises trip latch148, and raises trip lever 146 to disengage holding edge 154 from clutchdeenergizing member 152, so that the clutch is engaged and the shaft 54,together with clutch member 152 and non-repeat member 153 rotate aboutthe shaft axis. Upon about onequarter turn of shaft 54, the non-repeatsegment 153 engages trip latch 148 to shift the latter outwardly andrelease trip lever 146 for downward movement to locate abutment edge 154in position to limit clutch control member 152 to a single revolution.This clutch deenergization or engagement to effect a single revolutionof shaft 54 may be effected manually, as by a foot switch, orautomatically, if desired, as by sensing the proper position of a wireend to which a terminal is to be applied.

Depending from the solenoid 158 for up and down shifting movementtherewith is an indexing finger or dog 1611 suitably pivoted, as at 161,and spring-biased, as by a leave spring 162, or other suitable means inthe clockwise direction to a limiting position. The indexing finger ordog 160 is movable downwardly, and provided on its underside with aninclined surface 163 for engagement with one of the drive member pins118 to ride over the pin, and on its upper stroke to pull the pinupwardly and rotate the drive member 115 a predetermined angulardistance. In order to hold the drive member 115 in each predeterminedangular position of its indexing movement, there is provided a detentarm 164 pivoted, as by pin 165 at its upper end, and resiliently biased,as by spring 166 toward the circular array of pins 118. The detentmember or arm may be provided with a formation of groove 167 forreleasably receiving and holding a respective drive member pin 118, asshown in FIG. 3.

Thus, upon each rotation of shaft 54, as described hereinbefore, thedrive cylinder 115 is angularly shifted a predetermined amount, tolocate each successive pin 118 in held relation with respect to thedetent 164. It will now be appreciated that the carrier strip 20 is fedstepwise laterally across or through the instant apparatus by successiveangular displacements of the drive cylinder 15, together with the feedwheel or toothed sprocket member'l16. At each successive location ofcarrier strip 20, a terminal 25 is located in position between the upperand lower die parts 105 and 112, in which position the apparatus is atrest. That is, the drive motor 60 and flywheel 55 may be rotating, butthe clutch 66 is disengaged from the shaft 54.

The wire end may be inserted into the terminal barrel 27 positionedbetween the die parts, either automatically or manually, and thesolenoid 158 operated, either by signal from the operator or automaticsignal to effect movement of the die parts 105 and 112 toward eachother, as between the position of FIG. 1 and that of FIG. 5. With thedie parts 105, 112 closed to securely crimp the terminal 25 to thereceived wire end, the drive cylinder 115 is shifted rearwardly, by theaforedescribed coaction of cam 126, and lever 131, the sprocket wheel116 shifting the carrier strip 21 sufficiently rearwardly to reduce theholding action of the carrier or tape on the terminal being crimped tofacilitate subsequent separation of the terminal and tape.

For additional safety, particularly in manual operation, there may beprovided a guard plate 170 located in front of the die parts 105, 112and having an opening 171 permitting passage of a wire end to thecrimping location. The guard plate 170 may be pivotally mounted to thefront of the apparatus, as by a swingable member or hinge 172 whichcarriers an inwardly projecting member or pin 173. An interlock safetyswitch 174 may be located rearwardly behind the pin 173, and may beelectrically connected in the electrical power supply to the motor 60,so that the motor cannot operate unless the switch 174 is closed byclosing movement of the guard 170 and engagement by the pin 173.

From the foregoing it will now be apparent that the device of thepresent invention provides a terminal applying apparatus which appliesterminals from a carrier strip to wire ends, being simple, durable andreliable in construction, safe and high speed in operation, capable ofsubstantially complete automation, and which other wise fullyaccomplishes its intended objects.

Although the present invention has been described in some detail by wayof illustration and example for purposes of clarity of understanding, itis understood that certain changes and modifications may be made withinthe spirit of the invention.

What is claimed is:

1. Apparatus for applying terminals from a carrier strip to wire, saidapparatus comprising a frame, die holder means on said frame, diecarrier means on said frame mounted for movement toward said die holdermeans to a terminal crimping position and away from said die holdermeans to a terminal releasing position, strip feeding means on said dieholder means and mounted for movement in one direction to longitudinallystep a carrier strip through the space between said die holder andcarrier means and in another direction to displace the striptransversely away from and toward said die holder and carrier means, andoperating means connected between said die carrier means and stripfeeding means to move the latter intermittently in said one directionwhen said die holder and carrier means are out of said crimping positionand in said other direction when said holder and carrier means are insaid crimping position, to crimp successive terminals and dislodgecrimped terminals from said carrier strip, said die carrier meanscomprising a crosshead reciprocable toward and away from and having adie receiving groove opening toward saiddie holding means, saidcrosshead being provided with a cavity communicating with the interiorof said groove remote from said die holding means, a rotary fineadjustment cam of varying diameter selectively positionable in saidcavity to locate a desired diameter toward said groove, a roughadjustment block slidable in said groove away from said die holdingmeans to a position in limiting abutment with said fine adjustment camat said desired diameter, said block having a cavity opening into saidgroove away from said fine adjustment cam, and a rotary rough adjustmentcam of different diameters seiectively positionable in said block cavityto locate a desired diameter toward said groove, whereby said groove isadapted to receive a die selectively positioned in said groove byengagement with a desired diameter of said rough adjustment cam.

2. Apparatus according to claim 1, said fine adjustment cam having aspiral surface defining said varying diameters.

3. Apparatus according to claim 1, said rough adjustment cam havingangularly spaced chordal surfaces defining said different diameters.

4. Apparatus according to claim 3, said fine adjustment cam having aspiral surface defining said varying diameters.

1. Apparatus for applying terminals from a carrier strip to wire, saidapparatus comprising a frame, die holder means on said frame, diecarrier means on said frame mounted for movement toward said die holdermeans to a terminal crimping position and away from said die holdermeans to a terminal releasing position, strip feeding means on said dieholder means and mounted for movement in one direction to longitudinallystep a carrier strip through the space between said die holder andcarrier means and in another direction to displace the striptransversely away from and toward said die holder and carrier means, andoperating means connected between said die carrier means and stripfeeding means to move the latter intermittently in said one directionwhen said die holder and carrier means are out of said crimping positionand in said other direction when said holder and carrier means are insaid crimping position, to crimp successive terminals and dislodgecrimped terminals from said carrier strip, said die carrier meanscomprising a crosshead reciprocable toward and away from and having adie receiving groove opening toward said die holding means, saidcrosshead being provided with a cavity communicating with the interiorof said groove remote from said die holding means, a rotary fineadjustment cam of varying diameter selectively positionable in saidcavity to locate a desired diameter toward said groove, a roughadjustment block slidable in said groove away from said die holdingmeans to a position in limiting abutment with said fine adjustment camat said desired diameter, said block having a cavity opening into saidgroove away from said fine adjustment cam, and a rotary rough adjustmentcam of different diameters selectively positionable in said block cavityto locate a desired diameter toward said groove, whereby said groove isadapted to receive a die selectively positioned in said groove byengagement with a desired diameter of said rough adjustment cam. 2.Apparatus according to claim 1, said fine adjustment cam having a spiralsurface defining said varying diameters.
 3. Apparatus according to claim1, said rough adjustment cam having angularly spaced chordal surfacesdefining said different diameters.
 4. Apparatus according to claim 3,said fine adjustment cam having a spiral surface defining said varyingdiameters.